Solid-State Battery Module Foaming Restraint for Cell Expansion
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Solution Overview
Problem
The challenge is to effectively restrain solid-state battery cells within a battery module while preventing an increase in module size, as these cells expand and contract with usage conditions, making it difficult to attach them to vehicles without compromising energy density.
Innovation Solution
A method involving the arrangement of solid-state battery cells in a laminate direction without contact, using a restraining member with fixing portions and filling spaces between them with a foamable material that is then foamed, along with an optional potting material in an adjacent region for thermal conductivity, to create an elastic member that maintains the cells' position and absorbs expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cushion material is disposed in the battery module to absorb the displacement of the solid-state battery cell, then the battery cell expansion is absorbed, but the size of the battery module increases
Solution Approach 1:
The cushion material is designed with a foam structure containing numerous closed cells, providing compressibility and elasticity to absorb battery cell displacement while occupying minimal space. The porous foam structure allows the material to deform and recover, absorbing expansion forces without significantly increasing the battery module volume.
Solution Approach 2:
The cushion material's physical parameters (density, cell size, wall thickness) are optimized to achieve the right balance between compressibility for absorption and compactness for space efficiency. By adjusting these parameters, the material can provide sufficient displacement absorption while maintaining a small volume within the battery module.
2Quantity of substance
If the battery module size is reduced to maintain energy density, then the energy density is preserved, but the ability to restrain solid-state battery cells during expansion is compromised
Solution Approach 1:
The foam structure with closed cells provides both compactness (maintaining energy density) and mechanical compliance (restraining battery cells). The cellular structure allows the material to compress and expand with the battery cells, providing effective restraint without requiring large volumes that would reduce energy density.
Solution Approach 2:
The cushion material combines multiple properties in a single foam structure: elasticity for restraint, compressibility for space efficiency, and thermal conductivity for heat dissipation. This composite approach allows the material to perform multiple functions simultaneously while maintaining compact dimensions and high energy density.
3Strength
If a foamable material is used to create an elastic member, then the restoring force is enhanced and cell restraint is improved, but the manufacturing process complexity increases
Solution Approach 1:
The foamable material undergoes a phase transition from liquid to foam structure through a foaming process, creating a cellular network that provides elastic restoring force. This phase change allows the material to develop the desired mechanical properties for cell restraint while the process can be integrated into existing manufacturing workflows, balancing performance enhancement with process feasibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient restraint of solid-state battery cells under high loads while maintaining a compact module size, enhancing the restoring force of the elastic member and preventing energy density loss, by utilizing the foamable material's closed-cell structure and the potting material's reaction force.
Implementation Method 1
filling a space between the solid-state battery cells among the plurality of solid-state battery cells arranged in the laminate direction with a foamable material; and foaming the filled foamable material
Implementation Method 2
filling a second region adjacent to the first region with a potting material having thermal conductivity
Data Source
AI summary
A method for manufacturing a battery module including a plurality of solid-state battery cells includes a cell arrangement step of arranging the plurality of solid-state battery cells in a manner of being not in contact with one another in a laminate direction, and restraining the plurality of solid-state battery cells by a restraining member including a fixing portion configured to fix each of the solid-state battery cells, a filling step of filling a space between the solid-state battery cells among the plurality of solid-state battery cells arranged in the laminate direction with a foamable material, and a foaming step of foaming the filled foamable material.